Process for the production of hydrogen and carbon from hydrocarbons



g. 1 A. w. BURWELL I ,732

PROCESS FOR THE rnonucuon OF HYDROGEN AND cgasou FROM HYDROOARBONS Filed Sept. 16 1925 3 Sheets-Sheet 1 A TTORNE Y5.

WW'rMW Aug. 18, 1931. A. w BURWELL 1,819,732

PROCESS FOR THE PRODUCTION OF HYDROGEN AND CARBON FROM HYDROCARBONS Filed Sept. 16, 1935 s Sheets-Sheet 2 I INVENTOR I 5M Aug. 13, 1931.

A. w. BURWELL PROCESS FOR THE PRODUCTION OF HYDROGEN AND CARBON FROM HYDROCARBOINIS Filed Sept. 16, 1925 f/ydraaakba/r A an Em erafare. Acfvrf 4 amp 5/40? 6a.: S/bray sew/ 1 am C dds/7b Jada Jar-0665*- rersmon of Dryer pus/0y iafarf dfarmye Ola Decam- War IN VENT OR ATTORNEYS.

Patented Aug. 18, 1931 UNITED STATES "PATENT OFFICE ARTHUR W. BURWELL, F NIAGARA FALLS, NEW YORK, KSSIGNOR TO ALOX CHEMICAL CORPORATION. OF NEW YORK, N. Y., A CORPORATION 01 NEW YORK amocass FOR THE raonoc'rxon or HYDROGEN Am) cannon FROM nxnnocmons Application filed September 16, 1925. Serial No. 56,772.

carbons such as petroleum oil, .fuel oil, nat-,

ural gas, casing head gas and the like. I Hydrogen for use in the s nthesis of ammonia 'must be substantially ree of hydrocarbons and carbon monoxide. I

In the investigation of this matter the following observatlons have been made: When petroleum or other hydrocarbon vapor is heated to high temperatures for instance by being passed through a heated tube or over heated surfaces, it is more or less completely decomposed into its elements, go carbon and hydrogen, the decomposition being complete or substantially complete if the temperature is sufiiciently high. Up to certain temperatures no reaction takes place. As the temperature is gradually increased g5 lar hidrocarbon molecules if present begin to rea which are saturated and some unsaturated I and small amounts of hydrogen may be liberated. At still higher tem ratures the breaking up of the hydrocar ons proceeds further with the formation of methane, a greater roportion of smaller unsaturated hydrocar ons and some hydrogen. A further increase in temperature results in the formation of ring compounds such as benzol, toluol and their homologues, naphthalene, anthracene, phenanthrene, picene and many substituted bodies derived therefrom with a .further increase in the amount of hydrogen liberated. Up to this point very little elemental carbon' is formed. Now as the temperature is further increased the liberation of carbon begins with a further increase in the liberation of hydrogen accompanied first by a reduction inthe proportion of unsaturated bodies present in the gas followed b a reduction in the proportion of aliphatic ydrocarbon bodies both saturated and unsaturated present in the 'gas and finally by the disappearance of the aromatic bodies until at a up into smaller molecules some of' sufliciently high temperature only the two ultimate decomposition products, hydrogen and carbon, remain. some variations to the progress of the decomposition outlined above, for instance if the rise in temperature of the hydrocarbon vapor There are of course I is rapid, the proportions of hydrogen and carbon to the'other'bodies formed at a given temperature is'greater than when the same temperature is arrived at bya more gradual rise in temperature.

One method heretofore commonly employed for completing the decomposition of the hydrocarbons is by the use of 'high temperatures approaching the melting point of iron and oxidizing agents such'as air, oxygen or steam introduced into the hydrocarbon vapor under treatment. Such use of oxldlzing agents promotes the decomposition of the hydrocarbons giving a gaseous product free of hydrocarbons but has the disadvantage that carbon monoxide, a very objectionable-impurity and one which is very difiicult toremove,

is formed. The process of my invention differs from such prior methods of producing hydrogen from hydrocarbons in that no oxidizing agents are used and a feature of my invention' resides 1n the exclusion so far as is practlcable of all ox1d1zing influences. To

this end I not-only use hydrocarbons or mix tures whichvare free of oxygen compounds either. naturally or as a result of suitable preliminary treatment, but also carefully guard against any accidental or incidental admission of oxygen to the gas under treatment for instance in the form of water or steam or atmospheric air and even from iron rust on the retort walls. Any oxygen present in the gas under treatment will appear in the gaseous product in the form of carbon monoxide a'soline furic acid of about 66 B.,about five pounds of acid to a barrel of oil, according to the ,usual method of refining oil with sulfuric acid, then washed with water and finally with dilute alkali and finally dried by heating. Such a treatment will remove free and combined oxygen as well as water. The oxygen free oil must then be handled so that it is introduced into the decomposing apparatus without being mixed with or absorbingwater or oxygen from the air or any other oxidizing agent.

There are two possible methods of treating the hydrocarbon (1) by subjecting it to such heat treatment as to accomplish a substantially complete decomposition, and (2) I by subjecting the hydrocarbon to partial decomposition by the employment of lower temperatures and then removing residual hydrocarbons from the hydrogen gas by a suitable procedure such as compression, refrigeration,

and if desired or necessary, .finally scrubbing the hydrogen gas with a high boiling wash oilof low or negligible volatility. The process may also be operated either so that the liberated carbon will be deposited in massive form or in the form of lampblack as will ap- "of fire bric pear hereinafter the operation of the process so, that the carbon is recovered wholly or largely in the form of lampblack being preferred. The heating ofthe hydrocarbon preferably is accomplished by assing it in the form of gas or vapor throug a tubular retort. Two

orms of retorts suitable for this purpose are covery of lampblack and then to storage or a place of use-or apparatus for the fur-,

urification of the gas. When oil is illustrated in the accompanying drawings in which:'.

Fig. 1 is a vertical sectional view of a retort designed to-be heated by fire gases; Fig. 2 is a vertical section of a retort desi nod to be heated electrically; and

ig. 3 is a flow sheet of my preferred process. v

Referrinito Fig. 1, 1 is the retort housing 2 a furnace, 3 the retort tube nace 2. As illustrated, the retort tube stands vertically, this being preferred to eliminate as far as possible the deposition of carbon in the retort and to facilitate the cleaning ofthe retort, but the vertical arrangement of the retort is not essential. It may be arranged horizontally or slantingly. The retort illustrated in Fig. .1 may be heated by means of a coal, coke, gas or'oil fire, or the retort may be heated electrically as illustrated in Fig. 2.

-The hydrocarbon may be supplied to the the retort in any suitable form and manner,-

for instance in the form of a gas, vapor,

liquid or solid, one method being illustrated I in Fig. 1., according to which an'oil is de-.

livered inliquid form into a vaporizing chamber-heated by fire gases from the retort heating furnace, the resulting passing directly into the retort.

Referring to Fig. 2, 12 is the retort tube .made of suitable material such as fire brick,

13 is a covering of heat insulating material,

and 14 a metallic shell to make the retortgas tight. 15 and 16 are electrodes, 17 a mass of broken carbon and 18 a carbon rodjresistor. The retort is heated by the passage of oil vapors current, between the electrodes 15 and 16 I cape of gas and the hydrogen and lampblack .formed leave the retort through the outlet21 passing toapparatus'for the re- 'tion into hydrogen and carbon takes place.

Whether the carbon is deposited in the retort or carried out of. the retort in the form of lampblack, or both, depends largely upon the which may be of cast iron or earthenware or rate of decomposition of the hydrocarbon,

othersuitable refractory material, and 4' is a which in turn depends upon the rate at ,ba'flle chamber for separating carbon black which the temperature of the hydrocarbon from the hydrogen gas. The upper end of is raised and. upon the speed of movement of the retort tube 3 opens into an o 1l vaporizing the gases. In general a rapid heating and chamber 5 havin a removable closure 6 and rapid movement of the uses favor the pro- .the lower end 0 the retort tube communiduction'of lampblack.

ue to the practical cates with the lampblack-chamber4. Hydrodifliculties involved in the removal of carbon I carbon oil is supplied to the chamber -5 fromthe retort and further due to the fact through the goose neck 7 which forms a seal that lampblack is a'salable product, condiand prevents the escape of gas. Lampblack tions favoring the maximum production of is r'emovedffromthe baflle chamber by means lampblack and a minimum deposition of car- "of the-screw conveyor 8 and the hydrogen gas bon in the retort are preferred. It is furis delivered to storage or to apparatus for its ther observed that the more quickly the purification through the outlet pipe 9, 10 is lampblack is removed from the retort the beta door which may be opened to admit air to ter is the quality of lampblack produced.

the retort'while it is being cleaned, but is kept In addition to the observation that the closed during the operation of the hydrocarpresence of an oxidizing agent such as steam bon decomposing process, and 11 is the outlet or air is not necessary but is actually detri flue for the waste heating g'asesfrom the furmental in the decomposition of hydrocar- 130" nor desirable.

bons for the production of pure hydrogen, I have further observed that the employment of high temperatures approaching the melting point of iron in order to bring about a complete decomposition is neither necessary Ihave found that by heating oxide, the remainder being hydrogen, may

be produced. The temperatures referred to' are measured by means of a platinum-rhodium thermocouple i-n theheated space just outside of the retort tube.

These observations have led to the development of my preferred procedure illustrated on the accompanying flow sheet (Fig.- 3) to be described hereinafter. According to my preferred procedure hydrocarbon or mixtures of hydrocarbons substantially free of oxygen or oxygen compounds isdecomposed in two stages preferably using two separate retorts which may be identical in construction, each sta e being followed by a separation of lamp lack, and if desired a subsequent treatment of the hydrogen as for removal' of any undecomposed hy rocarbons and carbon monoxide.

The hydrocarbon is first purified if necessary for the removal of oxygen and is delivered into the first of the two retorts referred to hereafter as the low temperature retort. This retort. is operated so as to decompose the bulk of the hydrocarbon, produclng a gas consisting mainly of hydrogen with small amounts of unsaturated and aromatic bodies and a somewhat larger amount of methane. A temperature of 950 to 1000 C. in the first retort is suitable for this purse and gives an excellent quality of lamplack. If the retort is too long or'the gas is passed too slowly through it, a considerable amount of carbon will bedeposited in the.

retort. This is objectionable not only because it renders the cleaning of the retort necessary but the'quality of the carbon so produced is inferior.

By observationthe operator of any particular retort ma readily determine the speed at which the hy rocarbon shouldbe supplied 'to get the desired results. As a general rule which may'serve as aguide, I have found that the production of two cubic feet of gas each 24 hours for each square inch of heating surface on the inside of the retort gives good results. Considerable variation from the rule, depending upon the size and. shape of the retort, the kind of hydrocarbon under treatment and whether it is supplied to the retort in liquid or in gaseous form, and possibly other variable conditions, probably will be necessary. The mixed gases and carbon dust leaving thefirst retort are passed through a lampblack settling chamber and m the separated gases are delivered either to a gas holder-which should be set in oil to guard against the contamination of the gas with air or water, and then tothe second retort, or directly to the second or high temperature retort. The second retort is operated at a temperature of say 1140 to 1170" C.- This temperature insures the'rapld and complete decomposition of the hydrocarbons and at the same time is sufliciently low so .that it insures a long life for the retort. It

is noted here with reference to the temperatures specified that the decomposition of the hydrocarbon with a good yield of gas may be accomplished at temperatures of from 850 to 950 C. but the quality of the lamphis black formed at this temperature is not so I good. Moreover, when the first retort is operated at this low temperature and. the re sulting gas after passing through the lamp-' black chamber is heated in the second retort to the rapid decomposition tem erature ofthe residual hydrocarbons, there 1s danger of melting the second'retort. This may be explained by 'thetheory that the heating in the 1 first retort followed by the cooling incident to the removal of the lampblack forms hy drocarbon bodies which on being heated to their. decomposition temperature decompose suddenly or explosively with the liberation of a large amount of heat. This decomposition and liberation of heat is localized in the second retort and causes the retort to give way at the particular point at which the decomposition temperature of the hydrocarbons is ties, perhaps because the hydrocarbons formed at the higher temperature do not, upon cooling in the lampblack chamber, form theendothermic bodies referred to or because they are formed in smaller amounts.

If hydrocarbons are decomposed at ternperatures between 850 C. and say 950 C. there will be formed endothermic bodies in such quantity that on further heating in iron or other not sufiioiently refractory retorts, the amount of heat evolved'added to the temperature already maintained may bring the temperature to such a point that the retort will be damaged or destroyed. If, however, the retortbe madeof a material sufliciently refractory then the high temperature may be made useful in that it will aid in the decomposition of the more diflicultly decomposable hydrocarbons such as methane. It thus becomes possible to so select and maintain the Jtemperature of the first retort that by merely temperature in the second retort a maximum of decomposition will take place.

It is known that at a sufficiently high degree of heat it is possible to completely decompose methane into its elements. Such temperatures are so high that in many cases. the retorts are rapidly destroyed. However, I may employ another method of freeing hydrogen containing small amounts of methane from that-gas. Methane like other aliphatic hydrocarbons at certain temperatures is decomposed or partly decomposed I with the formation of other hydrocarbons of 1130 C. At higher temperatures eventhese higher molecular weight. I have caused the following reactions to-take place:

I find the'best temperature for the above reactions lies somewhere between 1030 and bodies are decomposed with the formation of some hydrogen, some carbon, and, in the presence of large quantities of hydrogen, of considerable amounts of methane;

I have found it possible to so regulate the rate of flow of gases and the temperature that all methane is decomposed and with the deposition of verylittle carbon. The aromatic hydrocarbons formed can be very easily removed leaving thehydrogen pure.

The gas leaving the second retort is then passed through the second lampblack settling chamber. The resulting gas is of sufficient purity for many purposes and may be used directly,-but since it may contain a relatively very small amount of carbon monoxide,

it being practically impossible to exclude all oxygen and it may also contain small amounts of hydrocarbons, it may be desirable to purify it. I have found that at '1700' C. carbon monoxide decomposes into carbon and carbon the metal catalyst as described above, then dried by means of'sulfuric acid, silica gel, phosphorus pentoxide or the like, then passed through a retort to decompose the methane and finally it may bepassed through a lampblack settling chamber to remove cgghon although this is usually unnecessary because of the very smallamount of carbon present.

It is to be understood that my invention eum oil with sulfuric .acid and with alkali and subsequently drying the treated oil, whereby the oil is substantially completely freed of oxygen and oxygen compounds, and passing the resulting oxygen-free oil in vapor Process which comprises treating a petrolform into contact with a solid body heated to a temperature of from about 850 to about 1170 C.

In testimony whereof, I afiix my signature.

ARTHUR W. BURWELL- dioxide both of which are readily removed from the hydrogen gas, but I prefer to remove the carbonmonoxideby passing the gas over a. suitable catalyst such as metallic nickel when. the carbon monoxide and hydrogen react as follows: I

CO+H=CH.,+H O.

- The) water may be removed by the use of a dehydrating agent such as calcium chloride or sulfuric acid and the methane may be decomposed by ahigh temperature .treatment similar to the treatment of the hydrocarbon.

described above On the filow sheet, Fig. 3, 1 have illustrated a complete purifying proccss which consists in first scrubbing the gas with sulfuric acid to remove any unsaturated and aromatic bodies which are more apt to be present if the retort treatment of the gas has been carried out at a low temperature. The

gas is then scrubbed with caustic soda to re move any acid spray and then passed over 

